Maintenance is a vital component of operating manufacturing and industrial equipment.
Any facility that heavily relies on equipments, machinery or other manufacturing system, needs regular maintenance to ensure everything is in good working order. Ideally you would want to address minor disruptions before they result in major shutdowns.
Two of the most widely adopted maintenance strategies within an enterprise asset management (EAM) system are Predictive Maintenance and Preventive Maintenance. Both aim to eliminate equipment downtime, improve reliability and prevent costly shutdowns.
Even though these strategies sound similar, they aren’t.
Read along to learn what predictive and preventive maintenance are, how they differ and how integrating both of them into your operations can be the best thing for your organization.
What is Preventive Maintenance?
You might be familiar with the concept of Preventive Maintenance. It is a proactive strategy where maintenance activities are scheduled at regular intervals to prevent problems before they actually occur.
The idea is simple, a collection of routine inspections and tasks like oiling, spare parts replacement, and calibration are performed to make sure all equipment operate efficiently and are less likely to experience unexpected breakdowns.
Preventive Maintenance Software: A program that helps businesses plan and execute preventive maintenance schedules.
Common Preventive Maintenance Practices:
- Scheduled inspections: Regular checks to identify any potential issues before they become major problems.
- Replacing worn-out parts: Components that are prone to wear, such as belts, filters, or seals, are replaced periodically.
- Lubrication and cleaning: Keeping equipment well-lubricated and free from dirt, dust, and debris helps to prevent unnecessary wear and tear.
- Calibration: Ensuring that machinery is operating according to specifications.
Benefits:
- Maintenance activities are scheduled in advance, making it easier to plan and allocate resources.
- Regular maintenance limits unplanned downtime.
- Extends equipment lifespan, offers better return of investments (ROI).
- Efficient and Proactive.
Drawbacks:
- Equipment may undergo maintenance even when not needed, resulting in unnecessary costs and planned downtime.
- Parts having significant lifespan are also replaced, contributing to higher operational costs.
- Inflexible to operating conditions, as maintenance schedules are fixed.
Preventive Maintenance Industries
Commonly practiced in industries with comparatively low operational complexity and predictable equipment failure patterns.
For Example, hvac system (HVAC), automotive fleets, and basic manufacturing machinery.
What is Predictive Maintenance?
Predictive maintenance is a more advanced, data-driven approach. Instead of performing scheduled maintenance at fixed intervals, this strategy involves using data analysis tools, computerized maintenance management system (CMMS), artificial intelligence (AI), and condition monitoring technologies to predict when maintenance is needed.
Like preventive maintenance, predictive maintenance is also a proactive approach. By analyzing the changes in temperature, vibration, and pressure through machine learning algorithms, predictive maintenance software can provide warnings about potential problems, allowing teams to take necessary steps proactively.
Predictive Maintenance Technologies
- Vibration analysis: Detecting unusual vibrations can indicate problems like misalignment or imbalance in machinery.
- Thermography: Infrared cameras are used to detect abnormal heat patterns, which may indicate electrical issues or overheating.
- Ultrasonic testing: Sound waves are used to detect leaks or cracks in equipment.
- IoT sensors: Internet-of-things (IoT) sensors, paired with AI and ML models, collect data and analyze data on various machine parameters to identify potential issues and predict failures.
Benefits:
- Maintenance is performed only when necessary, minimizing the chance of over-maintenance.
- Shorter downtime.
- Better inventory efficiency, spare parts are not replaced while being usable.
- Based on real-time data analytics.
Drawbacks:
- More complicated than preventive maintenance.
- Requires new technology and equipment for data collection.
- Maintenance of monitoring system—predictive system itself needs to be regularly updated and maintained.
- The system needs skilled personnel to interpret data reports and take timely decisions based on the insights.
Predictive Maintenance Industries:
Predictive maintenance strategies are mostly deployed in industries that depend on complex machinery with high operational costs.
For example: Aerospace, oil and gas, utilities, and high-end manufacturing.
These industries need to avoid costly downtime and cannot afford to replace parts before they reach the end of their useful lives.
Key Differences Between Preventive Maintenance and Predictive Maintenance:
Aspect | Preventive Maintenance | Predictive Maintenance |
Approach | Time-based and scheduled at fixed intervals, regardless of the condition of the equipment. | Condition-based and data-driven. Maintenance is carried out when data suggests it’s necessary, based on the real-time performance of the equipment. |
Cost Efficiency | Often leads to over-maintenance since parts are replaced or equipment is serviced even when it’s not needed. | Reduces unnecessary maintenance by focusing on actual equipment conditions, ultimately saving money and resources. |
Implementation | Easier to implement and requires fewer technological resources. It’s a straightforward process that involves scheduled service checks.
| Requires advanced technologies like sensors and software to monitor real-time data, making it more complex and costly to implement initially. |
Risk Management | Reduces the risk of equipment failure, but may not be optimized. Maintenance tasks might be performed too frequently or too infrequently.
| Reduces the risk of catastrophic failure by addressing issues only when they are likely to occur, making it a more targeted and precise approach. |
Technology | Minimal technology; manual inspections | Relies on IoT, AI, and advanced analytics |
Flexibility | Rigid schedule regardless of condition | Highly adaptable to equipment’s condition |
Downtime | Potential downtime if maintenance is missed
| Minimal due to timely interventions |
Combining Predictive and Preventive Maintenance: The Hybrid Approach
In reality, many organizations find that combining both predictive and preventive maintenance strategies yields the best results.
Using preventive maintenance for routine tasks—like lubrication, cleaning, or part replacement—and predictive maintenance for monitoring the condition of critical systems, businesses can enjoy cost-effective, efficient, and reliable maintenance practices.
Benefits of the Hybrid Approach:
- Cost optimization: Reduces unnecessary maintenance while ensuring high-priority equipment is well-monitored.
- Improved equipment reliability: Both planned maintenance and data-driven interventions work together to minimize downtime and extend asset life.
- Flexibility: Adapt maintenance practices based on equipment importance, cost considerations, and available resources.
Conclusion
Choosing the right maintenance strategy—predictive or preventive—depends on the nature of your operations, equipment, and available resources. Preventive maintenance is ideal for predictable, low-risk equipment, while predictive maintenance excels in complex, high-value systems where downtime can be costly. By understanding the strengths and weaknesses of each, businesses can develop a strategy that fits their specific needs and goals.
Need help determine which maintenance approach makes sense for your business? Contact us today to explore how we can help.
